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Dieci Workshop Manual


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Axle
Central driveline servicesClark Hurst axles01773 605444 for axle info.
Brakes- ATF oil reservoir in cab
Cable handbrake - adjust on top of axle at cable as well as in the cab at the handle mechanism. There is a 1.75mm
clearance setting on top of axle behind the lever that is connected to the cable. This is to allow the proper play in
the brake discs and to not let the park brake drag when not in use.
Brakes
The brakes are mounted in the centre of the axle housing and have an inspection bung in the housing so as you can
see the wear on the plates not easily due to confined space. There is a clearance setting for the brake discs of
2mm? between the brake discs. The brakes are fed from the master cly. Behind the guard, under the right hand
window, by 2 pipes 1 to the front and 1 to the rear. These pipes tee of to each side of the axle at the top of the each
axle it is possible to isolate each brake.
Negative Braking
The park brake works of the hydraulic pump on the rear of the engine. It operates by a switch on the dash that
opens a solenoid valve mounted on a cross member behind the transmission. This solenoid valve is live all the time
while the handbrake is in the off position. When the switch in the dash is switched on the power to the solenoid is
broken and the valve allows the pressure going through to the brakes in the front axle to be diverted. Thus pressure
holds the hand brake off and no pressure puts the hand brake on. The hand brake only operates on the front axle. It
is only controlled by the switch on the dash, it is not operated by the inching pedal which when depressed brakes
the drive train through the transmission, when you put the forward reverse lever into neutral it also brakes through
the transmission. Switching the ignition off will apply the hand brake.
The most likely area of trouble would be the solenoid block that controls the direction of the pressure. This valve is
easily found by following the pipe from the top of the front axle (there are 2 feed pipes going to the front axle one
will be for the foot brake working under foot applied pressure the other will be the hand brake working under
hydraulic pressure to keep the hand brake off) follow this pipe back to where it goes into a solenoid block and
check the electro solenoid on top with the ignition on and hand brake switch off there should be power to the
solenoid magnetising the valve spool. With the hand brake switch on there should be no power to this solenoid and
valve spool should not be magnetised. It is possible for the valve to be stuck in the valve block not allowing it to
operate, as it should. Remove the electric unit part and take out the valve and check for contamination. You can
check if valve is working by putting valve into electric unit and applying power though the circuit this way you can
see the valve opening and closing.
Any problems with the axle it self ring Clark-Hurth as they hold the warranty on all the axles and are more likely to change an axle rather
than work at it. The contact name is Stephen Newman (product support engineer) Ph. 01279 417247 fax 01279 416140 Mobile 07764
254425 email steve.newman@dana.com

Electro solenoid Negative brakeing valve


This section only relates
Hand brake circuit to Pegasus models

The solenoid valve is feed from the


main transmission pump by a pipe
coming from the under side of pump
which feeds this valve and the circuit
goes on to feed the valve that delivers
pressure to the transfer range gearbox to
select and hold the high and low range.
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Dedalus Axle with Negative braking Dedalus brakes only operate on front axle.
To release brakes for towing. Prop wheels to
stop them rolling. Remove bung from front and
one from the rear and take out spacer. Replace
bungs fully. There will now be no brakes on
machine.
It will also be necessary to engage neutral in
the range box. Beside the range box there is a
valve lever. Turn this lever 90 degrees to dump
any oil pressure going to selector valve. With
the selector rail that protrudes from range box
select neutral. This will show on the dash when
the range gear selected (green A light) indicator
is off.

Icarus, Samson Negative Braking To release the brakes for towing on these
machines there are 4 screws in the position
shown that have to be screwed in to depress the
negative diaphragm spring that clamps the brake
discs together. This will release the handbrake
but will not affect the foot brake. Again for
towing it will be necessary to engage neutral in
the range box as described above.
Mark the original position of the screws by
counting the number of turns needed to tighten
Screws in these positions in the screws, as these need to be the same for
returning the hand brake to its working state
again.

Brakes are mounted in the centre part


of axle and are the standard type oil
immersed plates clamped via a piston.
Piston is moved by oil from master
cylinder which is hydraulically
assisted at the master cylinder.
The piston has back up o rings for
added sealing effect.
The natural play between plates with
brakes off is 1.3 mm.
Brake plates can be seen via the level
bung.
On Negative braking the brakes are
held off by hyd pressure until the
handbrake is applied.
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Twist grip on forward reverse lever
This lever is only operative if the machine does not have a turbo fitted The non turbo machines sold to UK Forks
only, are the smaller 7-9 meter machines and have this half gear facility on the twist grip.
Problems encountered so far are the fuse FU10B (old cab) blowing when you twist the grip. In the turbo machines
the wiring going to transfer or range gearbox behind the front axle is taped up just above handle to turn of valve for
towing the machine on the road it is a small black connecter block and in it there is a diode bridging 2 connections.
Cut this diode out to relieve the problem. Alternatively you can lift the control panel on the right hand side of dash
the one with the jacklegs switches, cut and isolate the brown and white wire in connector no. X4 this is the power
feed wire to the twist grip. Machines that have not got a turbo fitted will have the half gear function working. This
works through the transfer or range gearbox via electric solenoid adjusting the angle of the swash plate in the
motor to a predetermined position. In the turbo fitted machines there is power enough in the engine to operate an
automatic speed selection controlled via hydraulic pressure valve fitted instead of the electric solenoid valve. It
works on hydraulic pressure rising from the main transmission pump. As the pressure rises the motor turns to drive
the axle and as the speed increases the swash plate changes angle automatically to give even more speed.

Forward reverse lever


The forward reverse lever controls a solenoid on the main transmission pump to control the direction of oil flow to
determine forward/reverse drive. The solenoid is the only one on the main transmission pump and is situated on the
side in a vertical position as shown below.

The sensor in the seat cushion and the sensor


on handbrake lever interrupt power for the
solenoid. The inching pedal does not break the
Forward electric power to the lever but does dump the
reverse oil going through the pump thus disengaging
control valve the drive and also applying the brakes via the
negative braking system on machines that
have it and by causing a back pressure in the
drive motor fitted behind transfer range
gearbox. It is important to keep oil clean as
the ports between solenoid valve and pump
have a small restriction hole which can block
Keep these ports
clean and cause loss of drive power

Hand Brake Lever


On the handbrake lever there is a sensor switch that creates 2 circuits one when h/brake of and one when h/brake
on. Wires to the plug are Grey/red (live) Orange/white(drive) and Blue/black (park light). This has power only if
you are sitting in the seat to activate sensor switch in seat. With the h/brake is off you have a circuit through
Grey/red to Orange/white. When h/brake is on you have circuit through Grey/red and Blue/black. Wires on the cab
side are Orange grey and blue wires from sensor are blue brown and black. (connecting grey to orange should by
pass sensor when seated in seat) Joining the 2 seat wires will by pass seat sensor.
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Hydrostatic Drive system
Transmission Transmission pump fitted on rear of engine with the hydraulic
Pump pump fitted on rear of this. Transmission pump is feed by
transmission filter in front of cab with CL46 hydraulic oil. This in
turn feeds oil under pressure (max 420 bar) to the drive motor fitted
behind front axle on range gearbox. The direction of the oil in the 2
Motor high pressure hoses is determined by the forward reverse valve.
Over all control of flow is regulated by the Inching pedal valve
fitted above inching pedal in the cab. This valve when opened by
depressing pedal dumps the flow of oil to the motor there by giving
control of movement to the pedal depending how far you depress
the pedal. This operation is not dependant on the revs of the engine
as you have control at idle revs and full revs allowing fast hydraulic
movement and slow drive motion. It is possible to do away with
inching pedal by joining pipes A and P together to form a
circuit. There are test points on both pump and motor for running
Inching pedal Valve tests to check pressures. The third pipe going to the motor is the
pilot pressure (24-27 bar) this controls the swash plate for
automatic speed increase or decrease on machines with turbo fitted
engines or the solenoid controlled hi / low gear on twist grip.
There are 2 pipes (not shown on diagram) that go to the
control valve on the motor it is important that these if removed go
back in the right position. If fitted wrong they will give the
symptoms of no drive power and when you lift your foot of the
accelerator it will give you the feeling that the brakes have been
applied. These pipes control the automatic stepless speed change
while driving.

The primary pump is situated in the


rear of the main pump and it is the
Primary Pump
primary pump that circulates the oil
from hydraulic tank to pump. The job
of the primary pump is to keep oil in
the main circuit of main pump to motor
but does not replace oil in this main
circuit on to it is needed through
natural loss. The oil in the main circuit
stays in this circuit continually so when
changing hydraulic oil it is necessary to
drain both pump and motor separately
so as put fresh clean oil in the system.
The primary pump also supplies
pressure for the low-pressure valves
operations.
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Checking Inching Pedal


Check inching pedal in cab Test pressures by fitting tee piece at pipe on pump at position 5 between the two-
electro valves. With the pedal up and engine idling there should be 20 bar, depress the pedal gradually and pressure
should decrease progressively to 0 bar.
Test calibration of pump to motor
Fit clock to position 4 and position 7 Test machine warm and in high range at full speed pump pressure should be
200-250 bar the motor should be mirroring the same pressures. Hold the revs on and apply the brakes hard the
pump pressure should rise to 420 and the motor pressure drop to 0. Adjust position 8 to calibrate.
Diagram
Position 2, pilot pressure 24-27 bar (engine idle and in neutral) 14mm coarse tread test point
Position 4, forward 400-420 bar. (in gear, brake on, high range and full revs 2500 rpm)
Position 4a, reverse (same procedure) 12mm coarse tread test point
Position 5, Adjusting screw for high pressure, normally set at 420 bar can be increased to 440 bar [test at position 4
forward or 4A reverse]
Position 6, adjust for smooth start off.
Position 7, Motor change test point 40 kph no 1-2 gear change. change point 240 bar
Position 8, this is for calibrating the change point between 1-2 automatic change normally set between 220 -240
bar tested at point 7.
Position Z, neutral setting, adjust if machine is dragging in neutral.
Position 9, pilot pressure relief valve. [if pressure is low fit a washer under spring to bring pressure up to 27 bar]

4 8
3

6
2
4 2

9
z
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ADJUSTMENT OF THE HYDROSTATIC UNIT

ATTENTION: The pipes and gauges etc. are to be connected/disconnected with the engine stopped and after
having released any residual pressure.

ATTENTION: The hydraulic oil temperature must be approximately 60 C to be able to adjust correctly. The
tolerance on the pressure values to be read is approximately 10 bar.

Starting adjustment
Engage forward gear at minimum rpm and the machine should not move.
The machine should start to move when the diesel engine is approximately at 1000 rpm.
If starting is not correct:
Loosen the register in position 6 to advance starting.
Tighten the register in position 6 to delay starting.

Feeding pressure
Using a 60-bar gauge, unscrew the cap in position 2 and remove it, then connect the gauge in its
place.
Rev the diesel engine to maximum rpm and the gauge in position 2 should show a pressure reading
of 27 bar.

If the pressure reading is lower than 27 bar:
Unscrew the cap 3 and add the dedicated spacers under the spring, then test the pressure again and
continue until the pressure reaches 27 bar.
If the pump is the 71 cc type, the adjustment is done by turning the dedicated register, which is fitted
instead of the cap in position 3.
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Maximum pressure of the hydrostatic pump


Using a 600-bar gauge, unscrew the cap in position 4 and remove it, then connect the gauge in its
place (use an extension so that the gauge reaches the cab).
Start the diesel engine.
Engage the fast mechanical gear.
Engage the fast electrical gear (if present).
Engage forward gear.
Hold the machine still by pressing the service brake pedal.
Rev the diesel engine to maximum rpm (with the machine still not moving).
The gauge connected in position 4 should read 420 bar.
If the pressure reading is not correct:
Unscrew or screw the register in position 5 until a pressure of 420 bar is reached.
Adjusting the pressure of the hydrostatic engine
Using a 600-bar gauge, unscrew and remove the cap in position 7 and connect the gauge in its place
(use an extension so that the gauge reaches the cab).
Using a 600-bar gauge, unscrew and remove the cap in position 4 and connect the gauge in its place
(use an extension so that the gauge reaches the cab).
Drive the machine at maximum speed on flat and even road.
Check if gauges 4 and 7 show the same pressure reading.
If the pressure readings are different:

Stop the machine and unscrew (to reduce) or screw (to increase) register 8 until the two pressures
are the same.
Keep the machine at maximum speed, start to brake slowly: gauges 4 and 7 rise simultaneously to
240 bar.
Gauge 7 should now suddenly drop to 30-40 bar, while that of the pump continues to rise to 420 bar.
Once the machine stops and stalls (pump at maximum pressure), the engine pressure should fall to 0.
If the pressure on gauge 7 falls before or after the 240 bar:
Stop the machine and unscrew or screw register 8 until you reach the correct setting.
Repeat the tests until you reach the correct pressures.

Upon completion of the tests, make sure the hydrostatic engine changes displacement correctly.
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Rexroth Tests & Valves Explanations

High Test Port pressure check point gauge 600 bar end. Top is forwards and lower is a bung and will need test
port changing to check reverse. Place machine in second gear, with feet hard on brakes, direction selected, rev
machine and observe pressure.
700 RPM 30 bar
1200 RPM 280 bar
1600 RPM 420 bar
2500 RPM 420 bar
High Pressure RV Screw in to raise out to lower high pressure 420 bar do not exceed 440 bar as you will
interfere with workings of combination valves.
Combination valves Set at 450 bar rear forwards front reverse. These are here to remove any sudden shocks.
But also act in charging the system with charge pump oil.
Motor Change Test Port Motor changes displacement during running. Max displacement means more torque
less speed.
Min displacement means less torque more speed.
Fit gauge 600 bar pressure end to high test port and motor change test port. Raise machine from the ground.
Move direction lever to forwards and put engine to full rpm. Pressure should be around 180 bar. Gradually
apply brakes, both gauges should rise together until between 220-240 bar is achieved, further application of
brakes will gradually decrease reading on motor change and increase to 420 bar on high test port at which point
motor change should read zero. NOTE do not prolong test as brakes could become overheated. If pressure is
correct but top speed is not achieved ie 18 kmh is top speed. Pipe dust can prevent valve from operating in
motor remove cap with X1 and X2 pipes attached. Remove carefully and clean.
Motor Change Adjustment If motor change pressure is different to above unlock nut and screw out to
decrease value and in to increase.
Min Displacement screw screw out to make machine faster, in for slower. Warning do not exceed 38 KMH.
Charge Test Plug Remove test plug and fit test port. Port is different size to high pressure. Pressure should
read 24-27 bar. If test port is not to hand you can fit 60 bar end gauge to high pressure test port be sure not to
put machine into drive, you will get the same pressure. Note if pressure is low you may experience a vibration
through the hydrostatic when driving.
Charge RV Charge pressure relief valve. Remove plug and insert washer to increase remove to decrease
pressure 24-27 bar.
Pilot Pipe T Point You will find two pipes coming from pump to motor called X1 and X2, these change the
displacement of the motor and is known as pilot pressure. If you place a T into one of these lines dependent
upon direction with a 60 bar end gauge you should with the applicable direction selected and brakes applied get
5 bar at idol and 24-27 bar 2500 rpm. Pilot pressure is governed by servo valve block (block with forwards and
reverse solenoids fitted). If pilot pressure is low suspect blocked orifice in valve block.
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Main Transmission Pump

To adjust the variable flow (5 bar at idle to 25 bar at full revs) from the transmission pump that moves the
swash plate in the motor and feeds the hydraulically assisted brakes.

The arrows point to the DA control valve. Page 16 of data sheet RE 92 003 refers to the function.
Basically, an oil path to control functions, internal and external via port Pst, is opened by this valve as engine speed
is increased. Adjustment affects the relationship between engine speed and control oil pressure.
The tamperproof cap will need to be removed, however doing so may adversely affect warranty. The seal lock nut,
13mm AF, will need slacking a little, and the M8 threaded pin can then be adjusted with a 4mm hexagon key. This
is a sensitive adjustment, 1/8th of a turn can make a considerable difference.
In order to increase control pressure at a given input speed, turn the threaded pin counter clockwise, noting the
original position. It may be seen that the transmission will attempt to drive at lower engine revs than desired,
stalling the engine, and requiring the DA to be reset to its original position.
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THE HYDROSTATIC SYSTEM

HYDROSTATIC SYSTEM WITH EZ

THIS HYDROSTATIC SYSTEM IS COUPLED WITH THE 60 KW ASPIRATE ENGINE


THIS SYSTEM HAS 4 GEARS, YOU CAN CHANGE THEM MANUALLY
IT HAS 2 MECHANICAL GEAR DUE TO THE GEARBOX (See next page : 2-speed gearbox)
IT HAS 2 ELECTROHYDRAULIC GEARS DUE TO THE MAX/MIN DISPLACEMENT OF THE
MOTOR (See next page: override)
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HYDROSTATIC SYSTEM WITH DA
THIS SYSTEM IS COUPLED WITH THE 74 KW TURBO ENGINE AND WITH THE 94 AND 103 KW TURBO-INTERCOOLER ENGINE
IT HAS 2 MECHANICAL GEARS DUE TO THE GEARBOX (see next page : 2-speed gearbox), AND, MAIN FEATURE, THE INFINITE GEARS OF THE
SYSTEM PUMP-MOTOR
WITH TWO SMALL HOSES FROM THE PUMP, THE SYSTEM SEND TO THE MOTOR A PRESSURE INFORMATION. WITH THIS THE MOTOR SET
ITSELF IN THE MOST SUITABLE DISPLACEMENT FOR THE WORKING CONDITIONS OF THE MACHINE

WHATS INCHING
THE INCHING IS A DEVICE THAT THROUGH A VALVE, POSITIONED UNDER THE THIRD PEDAL ON THE LEFT, LET YOU STOP THE MACHINE,
THIS VALVE CUTS OFF THE HIGH PRESSURE OILFLOW BETWEEN PUMP AND MOTOR.
YOU NEED THE INCHING TO CHANGE THE MECHANICAL GEAR AND IF YOU NEED TO MOVE THE MACHINE SLOWLY ALSO ON FULL
THROTTLE.
THIS DEVICE IS A BY-PASS ON THE CONNECTION BETWEEN PUMP AND MOTOR
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HOW TO REGULATE THE HYDROSTATIC SYSTEM

MINIMUM-MAXIMUM DISPLACEMENT:
You can do the regulation of the displacement just working on the screws on the top and on the bottom of
the motor (see picture). Dont do this regulation if you are not experienced, you can damage the hydrostatic
system and loose the warranty.

MECHANICAL ZERO:
You can regulate the mechanical zero working on the screw shown in the picture. Look for the maximum
displacement of the pump for each travel directions, the middle position is the mechanical zero.
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HYDRAULIC ZERO:
As the mechanical zero, if misregulated, let the machine start to move on idle. You can do the regulation
screwing or unscrewing the DA valve (as shown in the picture) until the machine start to move around 1000
rpm.

LOW PRESSURE:
Generally this pressure should be 24 bar on idle and 27 on full throttle. You can do the regulation changing the thickness as in the
picture, or working on the screw of the picture for pump with bigger displacement. This is the pressure of the INCHING device.
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MAXIMUM PRESSURE:
On the pump there are two antishock valve generally set on 440 bar, higher pressure could be dangerous for
the pump.
If you want to change this pressure you must replace the valves shown in the picture below.

REGULATION OF THE MAXIMUM PRESSURE:


To regulate the maximum pressure you can work on the valve shown in the picture, with this regulation you
can set the maximum pressure lower or higher than the antishock valves .
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TORQUE REGULATION:
This regulation, as the displacement regulation, is done by the supplier and the customer cant modify it for
any reasons, for this you can loose the warranty .
With the screw of the picture you can set on how many rpm of the engine you have the maximum torque of
the hydrostatic transmission.
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Low Pressure Line


Low pressure Pipeline Is feed from the under side of the transmisson pump not shown the above diagram. On some
machines it is a single pipe with a restrictor in the union and in certain machines it will be a tee piece with
restrictors in the tee piece. The low pressure pipe line feeds the hi-low range selector, 1-2 gear and electrical
controlled solenoids valves used on the main distributor (boom extension etc.). These machines normally have a
single pipe coming from the pump feeding in line to the distributor. On the machines with negative braking there
will be a tee piece on the pump giving two feed lines as above with also a line going to negative brake valve and
then on to the axle where it will go direct to the brake piston in the axle or in the case of the Zeus there is an
external ram to operate the handbrake. If the restrictors get blocked this will cause slowing down or stopping of the
different functions that are controlled by the low pressure line.
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Low pressure line Pegasus

Low pressure line works under 27 bar

Pressure can be tested from the test point on the pump to show what pressure is in the system

Pressure can also be tested at the point where the pipe no 110 leaves the pump
by removing pipe and fitting test clock to show what pressure is in the pump

Low pressure line is fed through pipe no. 110 from transmission pump to shut off valve.
Shut off valve feeds hi - low range selector valve through pipe no. 111
By turning off this valve you can isolate the hi - low range valve.
The low pressure line will then only feed the hand brake circuit through pipe no 115
The hand brake needs pressure to keep the brakes off.
The tee going into the hand brake valve has another out let which goes to the blocking rams on the back axle.
(any problems is this area will show up as an external leak)
By connecting pipe no 115 directly to pipe no 30 you can by pass the hand brake valve.
( you will have no hand brake in this instance)
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Steering

Steering is feed from the hydraulic circuit regulated by a priority valve which gets preference from the hydraulic
pump.
If dirt gets into this valve it can leave you with no power steering or leave it lumpy.
There is an orbital unit situated in cab under steering wheel.
A selector valve which is manually controlled in the fixed post machines, and electrically controlled in the rotation
machine. Giving you the 2 wheel steer, crab steer and 4 wheel steer positions.
The steering rams are fixed on the front and rear axles, and can be replaced as a complete unit or removed and seal
fitted as needed.
The 3 way selector valve is fitted between the orbital unit and the rams and diverts the oil as needed to get the
steering modes as selected. There are o rings in this selector valve and if they blow the steering can run out of line
as you drive along in the four wheel steer position.
On the little Dedaluss there is an accumulator fitted under the engine this is to do away with noise in the cab. With
out this accumulator a high pitch noise is generated through the pipe work and ends up in the cab.
On the Pegasus models the steering is feed through the central turret. The pipes can be followed via the numbering
on the turret itself.
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Range Box
The range box or drop box behind front axle that holds the transmission drive motor. This range box is controlled by hydraulic solenoid
pressure holding the box in either low or high range via a double solenoid valve mounted on the right side of range box on chassis. This
solenoid is electrically controlled from the hare switch on dash. Rock it one way with the inching pedal depressed and you have low range
with the A light just above the switch illuminated and no hare illuminated, rock it the other way and you have high range with the A
light illuminated and the hare illuminated. It is necessary to depress the inching pedal as this operation closes a switch mounted on the top
of the inching pedal to provide the electric power to the hare switch. This operation also helps to stop the machine from travelling, as it is
imperative that the machine is stationary while changing range gear to avoid that crunching sound while gears try to mate into one
another. New drivers need to be warned of this operation
The electric circuit for this system is found on page 3 of the wiring diagram. Power from fuse FU9B goes to S38 micro switch (above
inching pedal) then it goes to S8 hare switch (on dash) which in turn sends power down to either Y10 or Y11 solenoid (on chassis by
range box) depending on which switch way it is pressed.
The circuit for the A light and the hare light is fed from fuse FU1B going to H20 A light (Pilot light gears engaged) same feed for
F21 (Pilot light for Hare engaged). From these 2 pilot lights it then goes to their respective switches S34 micro switch for gears engaged
(on the range box right hand side running along selector rail) and micro switch S35 for Hare engaged (in switch itself).

Range Box

251 Solenoid valve that operates hi/low range in rangebox. This unit receives pressure from the shut of valve 250 which in turn is feed
from the transmission pump. This solenoid directs pressure to the housing ports number 45 in drawing which causes the selector 49 to
move from hi to low.

250 Shut of valve is used when you have to tow the machine. Shut of vale and manually select neutral gear in range box via rod 46
which protrudes from housing 45. This stops the motor 242 from back pressurising the transmission pump while being towed.

If the range box fills up with oil to the point that it over flows through the breather mounted on the top. It will be either the seals in the
selector housing or the seal in the transmission motor. To check which remove the motor back from the range box 50mm and run the
machine you will clearly see which is leaking.
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OPERATION OF THE BOOM WITH SIMULTANEOUS EXTENSION (10-11-12-13-14 metres)

WHILE THE BOOM IS EXTENDING, THE CYLINDERS MUST BE TIMED, IN OTHER WORDS THEY MUST REACH THE END-OF-STROKE TOGETHER
AT THE SAME TIME.
THIS CONDITION IS CRUCIAL BECAUSE IF THEY ARE NOT TIMED THE HYDRAULIC PIPES INSIDE THE BOOM COULD BREAK.
THE VALVE ILLUSTRATED IS SECURED TO THE BOTTOM OF BOTH CYLINDERS AND, IF THE SAME DO NOT REACH THE END-OF-STROKE
TOGETHER AT THE SAME TIME, IT ENABLES THE OIL TO CIRCULATE AND THEREFORE IT ENABLES THE CYLINDER THAT IS SLIGHTLY LATE
TO REACH ITS END-OF-STROKE THEN GET BACK IN TIME

IF THE BOOM IS NOT TIMED IT CAN ONLY CAUSE PROBLEMS IN THE RETRACTING PHASE AND IN PARTICULAR WHEN THE SECOND BOOM
EXTENSION IS LATE. THIS SITUATION GENERALLY CAUSES THE BREAKAGE OF THE HYDRAULIC PIPES AGAINST THE EDGE OF THE FIRST
BOOM EXTENSION THAT IS ALREADY COMPLETELY RETRACTED.
IF THE BOOM FAILS TO GET SYNCHRONISED AUTOMATICALLY, YOU ARE STRONGLY RECOMMENDED TO REPLACE BOTH VALVES AS SOON
AS POSSIBLE TO AVOID RATHER AWKWARD AND COSTLY BREAKAGES.
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Four section Boon with chains and how they work

The chains n 1 and n 3 are connected to the first part of the main section and to the last part of the second section
The chains n 2 and n 4 are connected to the first part of the first section and to the last part of the third section.
EXTENSION PHASE:
1. The extension cylinder pushes the first section.
2. The chain n 1 must go out so it pulls outside the second section.
3. During the extension of the second section the chain n 2 must go out so it pulls outside the third section.
RETURN PHASE:
1. The extension cylinder pulls the first section.
2. The chain n 3 must return inside so it pulls the second section inside.
3. During the return of the second section also the chain n 4 must return, so itll pull the third section inside
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Extension Rams
On the Machines with 3 sections there is an internal extension ram and an external extension ram. If these ever get
out of scyronization with one another ensure the check valves are operating OK. If this is not a suscess then it may
be a little valve that is situated in the centre of the ram, which equalises the pressures in the 2 rams. If this valve
gets blocked

Boom slow to rise even with high revs


If the boom will only rise or lower Verify that these plugs are intact
under high revs it may be that a seal with orings in place. Not all
may be gone in one of the ports distributors will have these plugs.
these can be checked by taking out They are there to allow you to
the ports along the top and the change the position of the tilt
bottom of the main distributor. The ram pipes. The tilt ram must have
symptoms will give the impression a relief valve in the circuit to
that the main pump has worn out allow the self levelling to work
and is not fit to lift the boom. with out bursting the tilt ram

Boom Drops 150mm on the down command from basket control

Drops suddenly, when you go to lower the


boom from the basket control. Will work ok
on the first command to lower but will drop
at the second command. (First press of the
button OK second press of the button boom
drops) You will need to change the 8mm
stud that is in the end of the check valve
with a modified one. (Modified one has an
(1mm) hole drilled up the centre of it for
20 mm, then a connecting hole drilled in
from the side) Important when you
remove the stud the boom will drop
8 mm stud. Drill a hole up the
centre for 20 mm and out the side
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INTERNAL EXTENSION JACK:

REMOVAL & ASSEMBLY

REMOVING THE JACK

FIT THE BOOM HORIZONTALLY AND COMPLETELY RETRACTED, THEN DISCONNECT THE 4 PIPES ON THE HEAD
OF THE BOOM AND PULL THEM OUT

OPEN THE REAR PANEL


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LOOSEN THE TERMINAL THAT HOLDS THE HYDRAULIC PIPES

PULL OUT THE PIPES DISCONNECTED FROM THE HEAD BY APPROXIMATELY 1 METER

IMPORTANT!!!

ALWAYS CHECK FOR THE PRESENCE OF ANY ELECTRICAL CABLES WITH 7 or 24 POLES
(GREY CABLES WITH RUBBER SHEATH)
IF PRESENT, DISCONNECT THE INTERNAL ELECTRICAL WIRES FROM THE SOCKETS ON THE BOOM HEAD AND
THEN FOLLOW THE SAME INSTRUCTIONS FOR THE HYDRAULIC PIPES
26

START THE MACHINE AND EXTEND THE BOOM UNTIL YOU CAN SEE THE INTERNAL CYLINDER PIN

REMOVE THE SNAP RING AND SHIM FROM THE SEAT


27
REMOVE THE PIN

START THE MACHINE AND RETRACT THE BOOM (THE LAST BOOM SECTION WILL OBVIOUSLY
STAY OPEN)
28
REMOVE THE SNAP RING AND SHIM FROM THE SEAT AT THE BACK OF THE EXTENSION
CYLINDER

REMOVE THE PIN


29
SLIGHTLY EXTRACT THE CYLINDER

DISCONNECT THE PIPES AND COLLECT THE OIL THAT DRAINS


30

EXTRACT THE CYLINDER


31

ASSEMBLE THE JACK

EXTEND THE CYLINDER BY APPROXIMATELY 2 METERS

INSERT THE CYLINDER


32

BRING THE PISTON EYE UP TO THE HOLE ON THE LAST EXTENDING BOOM SECTION

INSERT THE PIN, SHIM AND SNAP RING


33

CLOSE THE CYLINDER ALMOST COMPLETELY BY PUSHING IT, FIT THE LOCKING VALVE BACK
IN PLACE AND CONNECT THE TWO HYDRAULIC PIPES TO IT

START THE MACHINE AND RETRACT THE CYLINDER UNTIL THE SECURING HOLES MATCH-UP,
THEN INSERT THE PIN, FIT THE RIGHT SHIM, FIT THE LEFT SHIM, INSERT THE PIN
COMPLETELY WITH SHIM AND SNAP RING
34

RETRACT THE BOOM AND LEAVE THE EXTENSION CONTROL ENABLED FOR A FEW MINUTES
TO FILL THE PISTONS WITH OIL, THEN PULL THE PIPES OUT FROM THE HEAD AND CONNECT
THEM.

BLOCK THE PIPES BY TIGHTENING THE TERMINAL AND COMPLETE BY SECURING THE
ENCLOSING PANELS
Over Load Setting on new cab Dieci Teleporters
With monitor 4C.006568
Type with electric cable attached behind monitor
1. Put boom down horizontal with no load on the forks
2. Switch machine off.
3. Remove the fuse cover panel on the left hand side of dash there is a loose plug numbered X23, take this plug and join the two
wires in it with a connector. (Or a length of wire placed in the terminals)
4. Switch machine on and start engine
5. On the over load display panel press the TEST button once wait for orange and red lights to settle approximately 5 seconds.
6. Press the TEST button again and wait for light to settle.
7. Place a known weight on the forks (not necessarily the maximum lift weight) wheels straight on level ground.
8. Extend the boom out to the prescribed distance as marked on the lift chart.
9. Press the TEST button again wait for lights to settle. The buzzer will continue to sound until you remove the connector on
plug X23.
10. Test the machine that setting are accurate

If there is no boom actions from joy stick controls and the overload panel is dead.
It is possible to by pass over load system by pushing the red button under over load monitor.
If this does not work remove panel and connect wire number 3 with wire number 4 on the wiring connector on the rear of panel. This
will eliminate the over load system

Over Load Setting on new cab Dieci Teleporters


With monitor 4C.00015135
Type with plug behind monitor
1. Put boom down horizontal with no load on the forks
2. Switch machine off.
3. Remove the fuse cover panel on the left hand side of dash there is a loose plug numbered X23, take this plug and join the two
wires in it with a connector. (Or a length of wire placed in the terminals)
4. Switch machine on and start engine. 3 rd light orange and flashing
5. Press test an hold until 3rd light off and 1st on green
6. Press test once. When lights settle (5-10 seconds) power green light on and last red light on
7. Press test once. When lights settle (5-10 seconds) last red light on
8. Place a known weight on the forks (not necessarily the maximum lift weight) wheels straight on level ground.
8. Extend the boom out to the prescribed distance as marked on the lift chart.
9. Press the TEST button again wait for lights to settle. The buzzer will continue to sound until you remove the connector on
plug X23.
10. Test the machine that setting are accurate

If there is a lot of noise and over load on all the time the sensor is most likely to be at fault
If there is no power showing on the monitor -- It is most likely to be the monitor at fault

The over load can be by passed by the following procedure


1. remove overload panel from dash
2. on the back of the red over ride button disconnect the blue wire
3. connect the blue wire into the orange wire at the other end of over ride button
4. disconnect the plug from the rear of the monitor

Red over ride button switch

Blue wire 0range wire

Black wire Orange wire


36
OVERLOAD DEVICE SETTING
On single cell overload

- WITH THE MACHINE OFF, BRIDGE THE CONNECTOR X23 PLACED UNDER THE ELECTRICAL PANEL BOARD (ON THE LEFT
HAND OF THE STEERING WHEEL)
-

- TURN ON THE MACHINE, BOOM RETRACTED AND IN ORIZONTAL POSITION, THE YELLOW LED IS ON, PRESS THE BUTTON
TEST FOR AT LEAST 2 SECONDS AND THE GREEN LEDS SHOULD BE ON.

- PUSH AGAIN TEST AND AFTER AROUND 4/5 SECONDS THE YELLOW LED WILL BE ON, PRESS TEST AGAIN AND AFTER 4/5
SECONDS THE RED LED SHOULD BE ON.

- LOAD A KNOWN WEIGHT ON THE FORKS (FOR EXAMPLE : 1000 KGS.) AND EXTEND THE BOOM (ORIZONTAL POSITION) TILL
THE POSITION WHERE THE ALARM SHOULD PUT IN ACTION (REFERRING TO THE LOAD CHART).

- WAIT UNTIL THE BOOM STOP TO OSCILLATE AND PRESS TEST AGAIN, AFTER THIS ALL THE LED WILL BE ON AND YOULL
HEAR THE SUOND OF THE BUZZER
- STOP THE MACHINE (OFF).
- REMOVE THE BRIDGE ON CONNECTO X23 AND TRY THE CORRECT WORKING OF THE MACHINE.
37

FOR A DOUBLE OVERLOAD CELLS MACHINE

THE REGULATION MUST BE CARRIED OUT AS FOLLOWS

WHILE THE MACHINE IS OFF, WITH THE BOOM CLOSED


AND HORIZONTAL TO THE GROUND, TURN THE KEY TO
THE "ON" POSITION.

MAKE A BRIDGE ON THE "X23" CONNECTOR AND TURN ON


THE MACHINE.

PUSH THE "TEST" BUTTON OF THE DISPLAY ONCE: BOTH


YELLOW LEDS WILL TURN ON.

PUSH AGAIN THE "TEST" BUTTON AND KEEP IT DOWN FOR


10 SECONDS: THE SMALL GREEN LED WILL TURN ON.

PUSH THE "TEST" BOTTON ONCE MORE: THE GREEN LED


WILL START BLINKING. AFTER A FEW SECONDS, THE
YELLOW LED, CORRESPONDING TO THE STABILIZER
TURNS ON AND THE GREEN ONE WILL BE PERMANENTLY
ON.
38

MOVE THE STABILISERS DOWN. THE LIGHT ON THE


INFERIOR INSTRUMENT PANEL (DOWN LEFT) TURNS ON.
PUSH "TEST" AGAIN AND BOTH STABILISERS' LEDS (THE
GREEN AND THE YELLOW ONES) WILL START FLASHING).

AFTER A FEW SECONDS, THE FORKS' RED LED WILL TURN


ON. LIFT THE STABILISERS UP. ALLS LED WILL TURN OFF.
PUT A KNOWN LOAD ON THE FORKS AND SLIP OFF THE
BOOM TILL THE POSITION BY WHICH THE ALARM IS
WANTED TO GO OFF IS REACHED (SEE THE LOAD SCHEME
OF THE MACHINE).

PUSH THE "TEST" BOTTON AGAIN AND THE RED LED WILL
START BLINKING. AFTER A WHILE IT WILL BECOME
STEADY AND THE STABILISERS' YELLOW LED WILL ALSO
TURN ON. MOVE THE STABILISERS DOWN: THE FEET'
LIGHT WILL TURN ON. PUT A KNOWN LOAD AND SLIP OFF
THE BOOM UNTIL THE POSITION BY WHICH THE ALARM IS
WANTED TO GO OFF IS REACHED (SEE THE LOAD SCHEME
OF THE MACHINE).

PUSH THE "TEST" BUTTON AGAIN AND THE RED LED WILL
START FLASHING. AFTER A FEW MOMENTS IT WILL BE
STILL ON, BUT STOP BLINKING; THE BEEPER WILL START
RING. ALL LED WILL SWITCH OFF, EXCEPT THE GREEN
ONE.

TURN THE MACHINE OFF, REMOVE THE BRIDGE FROM THE


"X23" CONNECTOR AND CHECK THE RIGHT SYSTEM
CALIBRATION.
39

Over load wiring diagram and setting instructions Old Cab Machines
Control box and electrical lead Part no BEP0203/LE
Axle sensor (extensimeter transducer) part no BEP0204

The axle sensor is tightened down to a torque setting of 7 kgs. (Make sure the under side of sensor and axle are clean.) The wires are
feed up the chassis to the control box and connected into the box as described in the drawing. With the boom down and no load on it,
switch on the ignition and turn on the overload the buzzer should sound overload (not always). Screw the adjusting screw (1) beside
the red diode in (clockwise) until the buzzer or overload goes off. (if the overload was not on when connections were made screw
adjusting screw (1) out anticlockwise until the buzzer comes on and then screw in to buzzer goes out)
Set the over load by putting a measured weight on the forks and extend out to specified distance on the loading chart. Turn adjusting
screw 1 clockwise or anticlockwise as appropriate to put the red diode on (also sounds the overload buzzer and the red warning light
on dash). Then retract the boom 1 meter and adjust adjusting screw no. 2 until the yellow diode comes on (also lights the yellow
warning light on dash). When set, the yellow warning light should come on 1 meter before the overload comes into action. The little
brass screws used for adjusting are very fine and do not actual screw in or out and may require a considerably amount of turning to
reach the setting points.
Over load stuck on, boom will not come down or out, green light on in the middle of circuit box and the red and yellow light
out.
Take brown and black wire off bottom board and try machine, if machine works, replace wire and tap the orange box on the same
part of the board lightly (the circuit may be stuck).

Red
Black Wiring for
overload
White
sensor
Yellow

Orange box - relay


40

Auxiliary Wiring Lay outs

Plug into boom


Has appox. 24 wires all black all numbered 1-24. These numbers match up with numbers in
the plug and are fitted 1-1, 2-2, 3-3 etc.

Dummy plug on head stock wiring. Plug on Winch on older Pegasus


Position 11 is looped to position 18 Red goes to 2
14 17 Black goes to 3
15 16 Purple goes to 18
22 23 Blue goes to 11

BEK6095/LE Radio remote control in Plug on winch 3.8T, 2.5T, 1.2T and 0.6T
basket. Wire -- Plug
Plug to head stock, Red -- position 3
Wire Plug Black -- position 4
1 + 4 go to position 1 Loop wire -- positions 1, 6, 16
2 goes to 2 + earth looped to 4
3 goes to position 16 0.6T
5 goes to position 6 loop wire -- positions 1, 6, 7, 16
6 goes to position 17 Blue and brown -- joined in a connector

Over load wiring under seat old cab

Power lead
1 1 red wire
1 2
Fuse 2 black wire
2 3 3 white wire
3 4 4 yellow wire
4
Sensor cable 5
6
7 Red diode
8 Yellow diode
Sensor cable 9
1 - Grey
2 - Black 10
11 -Yellow/ red 11
Brown/black 12 1
2
3
41

Relays in dash Old Cab Machine

K1 Starting motor
K2 Timer K8 K7 K6 K5
K3 main beam
K4 forward reverse
K5 seat safety
K6 reverse buzzer
K7 anti tipping
K8 anti tipping
K4 K3 K2 K1

Air conditioner gas charge procedures


Vacuum for hour the compressor check for leaks, add 50 grams of oil, fill with 850 g of R134 gas ( or any
other gas used for car air conditioners).

Electrical connection under the seat:


3 plugs
N 1- 2 wires plug (1 Black, 1White & Red)
N 2 4 wires plug: from machine: 2 Brown , 1 Red & Green, 1 Black
I I I
Blue Green Black

N 3 4 pin plug with 3 wires only : Black, Gray & Black, Gray & Yellow
I I I
Black Blue Red

Basket Control 14m Prearranged Machine

On machines with Danfoss system the speed on the ram is controlled by the joy stick ( in how far you push it )
On machines without Danfoss and have the yellow control box with push button controls the speed of the ram
action is controlled by a valve beside the main distributor behind the panel under the right hand cab window.
42
Derek Howarth Iveco UK ph. 01606 541031 fax 01606 541124
Engine Torque settings old Iveco 8045-SE.00.7.00 engine

Con. Rod stud 1st step 40Nm 2nd step 60 degrees


Main brg stud 1st step 80 Nm 2nd step 90 degrees
Flywheel studs 1st step 40Nm 2nd step 60 degrees
Front pulley nut 294Nm
Head 1st step 70 Nm 2nd step 90 degrees 3rd step 90 degrees
Compression pressure At 200 rpm 16 bar
Injector nozzle calibration 260 bar
Injector protrusion 0.3 mm-1.1mm
Tappet setting 0.30 mm Cold or hot Inlet and exhaust
Cam lift 5.67
Valve guide dia. Inside 8.023-8.043 Outer 13.993-14.016
Valve depth below head Inlet 0.7-1.0 Outlet 0.7-1.0
Thermostat on/off 79 degrees
Turbo charger Garrett
Oil pressure Minimum 0.7 bar Maximum 2.5 bar
Injection pump type VE4 / 12F 1150 L 782
Firing order 1-3-4-2
Camshaft diameter 1= 51.000 2 = 50.500 3= 50.000
Crankshaft trust washers 3.378 3.429
Crankshaft end float 0.082 0.334
Brg under size range 1st = 0.254 2nd = 0.508 3rd = 0.762
Main brg housing dia 84.200 84.230
Main journal dia std. 79.791 79.810 Big end dia std 63.725 63.744
Big end con rod bore 67.407 67.422 Small end bore dia 38.004 38.014
Cylinder dia 104.000
Piston clearance in cly 0.174 0.212
Piston protrusion 0.335 0.761
Piston dia at skirt 103.812 103.826
Compression ratio 16.5 : 1
Cylinder capacity 3908 cm3
Stroke 115mm
43
44

New Iveco Engine NEF family

19/11/04:
IVECO NEW ENGINES:
NEF-NA-60 KW NON TURBO ENGINE
NEF-TC-74 KW TURBO ENGINE
NEF-TCA-88 KW TURBO INTERCOOLER ENGINE

PEGASUS - DEUTZ NEW ENGINE:


BF4M2012C 103 KW TURBO ENGINE
45
Filters used on Dieci Machines and prices

Agri, Runner, Icarus, Samson, Deadlus and Pegasus (old cab)

Hydraulic (screw on) x1 BHC3012


Hydraulic (in the tank) x 2 BHC0105
Engine oil (turbo engine) x1 1F.1902047
Engine oil (non turbo) x1 1F.1901603
Fuel x 2 1F.1930010
Air filter outer (turbo engine) x1 1F.8014390
Air filter inner (turbo engine) x1 1F.8015449
Air filter outer (non turbo) x1 1F.8015448
Air filter inner (non turbo) x1 1F.8014430
Mixer engine as above
Hydraulic filer x 2 BHC3008
Dumper engine as above
Hydraulic filter x 1 BHC3008

NEW CAB MACHINES Icarus, Runner, Samson, Zeus New cab


1L.2175046 Fuel filter 1 1F.1930010 Fuel filter 1
BHC5030 Pre fuel filter 1 BHC5029 Inner air filter 1
BHC5029 Inner air filter 1 BHC5028 Outer air filter 1
BHC5028 Outer air filter 1 BHC5031 Engine oil filter 1
BHC5032 Engine oil filter 1 BHC3012 Hydraulic filter 1
BHC3012 Hydraulic filter 1 BHC0105 Hyd filter in tank 2
BHC0105 Hyd filter in tank 2 1F.504013617 Engine Belt 1
1F.504031929 Starter motor 1
New Cab All Models Dedalus 26-6

3E.1606007V-C Top door glass 1F.1930010 Fuel filter 1


3E.1606001V-B Windscreen glass BHC5031 Engine oil filter 1
3E.1606003V-C Right hand side glass BHC3012 Hydraulic filter 1
3E.1606002V-B Open able roof glass BHC0117 Hyd filter outside tank 1
3E.1606008V-A Fixed door glass 1F.8015449 Inner air filter 1
3E.1606004V-B Glass behind door 1F.8014390 Outer air filter 1
3E.1606006V-A Rear window glass
1F.504013617 Engine Belt 1
4C.114014 Ignition key
1F.504031929 Starter motor 1
3E.31408 Inner door handle
3E.31336 Outer door handle Dedalus 28-7, Dedalus 30-7
3E.31407 Inner door lock BHC0107 Hyd filter in tank 1

Recommended oils for Dieci Machines

Engine 15/40
Hydraulic oil CL46 Do Not Use Synthetic Oil
Axle and gearbox SAE 85W90
Brake Fluid Dextron 2 (ATF)
Grease Super Grease G2
Service schedule for Agri Deadlus Runner Icarus and Samson Zeus
46
Service and maintenance schedule for Dieci Pegasus
Group Description Period in hours
80 400 800 1200 Capacity
Engine Replace engine oil * * * * 9 litres
Replace engine oil filter * * * *
Clean air filters * * * *
Replace air filters *
Fuelling Replace fuel filter * * * * 145 litres
system Clean fuel pump filter *
Cooling Check coolant level * * * 14 litres
system Replace coolant *
Hydraulic and Check levels * * * 126 litres
Transmission Replace oil in system *
Circuit Replace external filter * * *
Replace internal filter *
Transmission Replace oil In pump * * * 4 litres
Pump
Transmission Replace oil in motor * * * 4 litres
Motor
Electric Check battery electrolyte * * * *
circuits level * * * *
Check alternator belt * * * *
Differential Check oil level in sump * * * 8 litres
axle Replace oil in sump *
and gearbox Check oil level in hubs * * *
Replace oil in hubs *
Check gear oil level * * *
Replace gear oil level *
Tighten wheel nuts * * * *
Various Check tyre pressures * * * *
Check turret rotation oil * * * *
level *
Change turret rotation oil * * * *
Check brake oil level *
Change brake oil level * * * *
Check accelerator oil level *
Change accelerator oil * * * *
Grease all points * * * *
Check turret motor bolts * * * *
Check wear pads * * * *
Check Parking Brake * * * *
Check Lights * * * *
Check Hyd Hoses * * * *
Replace Crystals bag in Turret *
Filters used in Pegasus 25m Labour charges
1L.2175046 Fuel filter 1 Short service takes 3 hours
BHC5030 Pre fuel filter 1 Major service at1200 hours takes 4.5 hours
BHC5029 Inner air filter 1
BHC5028 Outer air filter 1
BHC5032 Engine oil filter 1
BHC3012 Hydraulic filter 1
BHC0105 Hyd filter in tank 2
47
Service and maintenance schedule for Dieci Icarus Runner Dedalus Zeus Samson

Group Description Period in hours


80 350 650 1000 2000 Capacity
Engine Replace engine oil * * * * As 9 litres
Replace engine oil filter * * * * the
Clean air filters * * * * first
Replace air filters as needed * 1000
Fuelling system Replace fuel filter * * * * 145 litres
Clean fuel pump filter *
Cooling system Check coolant level * * * * 14 litres
Replace coolant *
Hydraulic and Check levels * * * * 126 litres
Transmission Replace oil in system *
Circuit Replace external filter * * *
Replace internal filter *
Transmission Replace oil in pump * * * 4 litres
pump
Transmission Replace oil in motor * * * 4 litres
motor
Electric circuits Check battery electrolyte * * * *
level
Check alternator belt * * * *
Differential Check oil level in sump 8 litres
axle Replace oil in sump *
and gearbox Check oil level in hubs
Replace oil in hubs *
Check gear oil level
Replace gear oil *
Tighten wheel nuts * * * *
Various Check tyre pressure * * * *
Check brake oil level * * * *
Change brake oil *
Grease all points * * * *
Check Wear Pads * * * *
Check Lights * * * *
Check Hydraulic Piping * * * *
Check Safety equipment * * * *
Check Parking brake * * * *

Icarus Dedalus Runner Samson Zeus Old Cab

New Cab
Hydraulic (screw on) x1 BHC3012
Hydraulic (in the tank) x 2 BHC0105
1F.1930010 Fuel filter 1 Engine oil (turbo engine) x1 1F.1902047
BHC5029 Inner air filter 1 Engine oil (non turbo) x1 1F.1901603
BHC5028 Outer air filter 1 Fuel x 2 1F.1930010
BHC5031 Engine oil filter 1 Air filter outer (turbo engine) x1 1F.8014390
BHC3012 Hydraulic filter 1 Air filter inner (turbo engine) x1 1F.8015449
BHC0105 Hyd filter in tank 3 Air filter outer (non turbo) x1 1F.8015448
Air filter inner (non turbo) x1 1F.8014430
48
49

This is the procedure to cut out the overload from stopping the boom movements but still maintain the overload monitor

Follow the instructions to eliminate the need for the over ride button
Remove the two wires from the key switch S16 and isolate them. Take two new wires and connect them into the key switch S16 Then
proceed to connect the other ends into the red button switch S40 as shown. With this done you should be able operate the machine
with the over load on but not cutting out the boom movements when the red lights come on the overload monitor. The green lights
should indicate the state of safety but it will be the operator who controls when to stop lowering or extending as is safe.
50
Greasing Points
51
52
53
54

If you want machine to drive while


turret is at 90 degrees remove this
diode it is the second one down in
this position

This switch is operated by


inching pedal to give power
to the range change switch.
Pedal depressed power to
switch, pedal up no power to
switch

This plug is used to set the over load


system on the fixed post machines (does
not be used on the Pegasus models). Plug
a connector on this wire that joins these
wires together.
55
Pegasus losing oil from the foot throttle reservoir
If there is oil coming [over flowing] from the reservoir in the cab it will be from a high pressure line in the turn
style, which is leaking across into the low pressure line of the foot throttle. Take the plate of under the boom
that is above the turn style distributor and you will find the low pressure line from the throttle master cylinder
goes into the distributor at the rear, on pipe number 309. Take this pipe with union and transfer it to the front
side of distributor to position no. 15 which is the second place down from the top take the plug out of this and
put into position number 10 which is where you removed the throttle pipe from. Put the throttle pipe and union
into this position number 15. Do the same procedure with the bottom end of the distributor. Take the pipe from
number 10 and fit into number 15.

Hi pressure
Pipe 309 15
56

Pegasus

3 wires in each solenoid plug. 1. black earth , 2. Purple 12volts live


when trigger pulled on joystick and the engine is running. 3.
Individually coloured wire that has 6volts when engine running and
trigger is pulled on joystick, changes as solenoid is operated, to
extend a ram it will rise to 9volts. To retract a ram it will fall to
3volts. When engine not running and ignition on or off, there will be
no power at this plug.

Transducers for tilt ram is


mounted here and directly
13mm bolt is a shock valve
(ball and Spring) 2 in each under this one whereas the
slice. Check if movement transducers for the lift ram is
is jerky. fitted on check valve at ram

Relief valve is situated just


behind manifold and just
These pipes go to dump above visible allen key. The
from this manifold relief valve is an allen key it
self and is set at 260 bar. This
is for the distributor not for
Live pipe pressure into
the individual pumps.
distributor

Jackleg Distributor

Control valve for the


jack legs in that it sends
hyd pressure to the If there is any spare wires
distributor to work jacks going through the turret they
normally power goes to will be found here in the
main distributor form of a loose plug.

Test point for main


pump 170 bar for all By pushing button in the top
operations on lower of this solenoid you can test
turret. valve. In is pressure to
jacklegs
This valve controls the
high pressure for the upper
turret 260 bar by allowing Sway control valve
the second pump to put
pressure into the system by
shutting the dump pipe
57
Joy Stick in Pegasus controls under seat in cab

Pegasus Boom Sensors

In frosty conditions switched can stick and give false readings

Switch on cab side of boom that reads the minimum height if it sticks you will not be able to extend the boom .

Switch on the cab side of boom that reads maximum height if it stick you will not be able to lower boom.

Switch on the rear of boom on cross shaft behind yellow end cover if it sticks the jack legs will not work.

Sensor at rear of boom behind yellow cover that reads boom extension out extension if it is faulty will affect the
basket control if a basket is attached. In the basket mode you will not be able to drive the machine.
58
Replacement of the booms angle and extension reading cable reel Pegasus 3B6

1. Open cover from the old reel


2. Disconnect the 6 wires and remove the electrical cable
3. Remove the cable holder at the top of the boom
4. Remove the old reel
5. Place the new reel on side of the boom
6. Re-connect the electrical wires (see enclose diagram)
7. Close the cover
8. Put the boom at 0 degrees horizontal and fully retracted
9. Fix the steel cable at the booms head
10. Remove the plastic strip holding the cable near the reel
11. Set the cable, by pulling it in or out, until you read 4.9 on the R position on the 3B6 display in the cabin
( See picture)
12. Verify that the machine works correctly.

Ref: N 11
This figure 6.1 (R)should
read 4.9 with the boom
fully retracted and
horizontal.

Wiring diagram for wires in cable reel

1 Brown
2 White
3 Green
4 Pink
5 Yellow
6 Grey
59
Instructions for replacing (or repairing) the 3B6 cable winder

-First, secure the surviving cable in the appropriate ring at the head of the boom.
-Check to make sure that when the boom is completely extended, the cable is sufficiently long (if it is too short,
replace the entire cable winder with a new one, paying attention to the electrical connections inside it).
-Position the machine on the stabilisers.
-Position the boom completely extended and completely raised (70 / 72 / 74 dependently from the model of
Pegasus).

-Now you have to work on the display in the cabin. Enter into programming mode: switch the key on the starter
panel off and then on again (the motor must be on); the data on the display will disappear.
-Wait a few seconds until the display shows the eprom model (UM257 DIECI), then quickly press ENTER just
once.
The page for setting the password should appear (CODE: 4477); if not, switch off the panel and start over
again.
Above the numbers is an asterisk that can be moved using the INDEX key. When the asterisk is above a
number, its value can be increased or decreased using the + and - keys.
Enter our password, i.e. CODE: 4482 ( 3577 with UM394 if with frontal carriage), , then press ENTER.
-At this point, the main page appears on the display. Use the + and - keys to go to the page for calibrating
the boom in the maximum conditions: 13 Transd. Max .
-Press ENTER and INDEX to confirm the calibration in machine open conditions.
-At this point, completely close and lower the boom (-4) to calibrate it in its minimum conditions.
- Use the + and - keys to go to the page: 12 Transd. Min .
-Press ENTER and INDEX to confirm the calibration in machine closed conditions.
-At this point you need to save the data. Use the + and - keys to go to the page 01 Save , and press ENTER
to activate the save command.
A message will indicate that the save operation is in progress: Save in progress .
At the end, the display shows the message: Done.
You have now finished. All you have to do is switch off and re-start the machine to exit from programming
mode, then test for correct operation of the machine.
IMPORTANT NOTE: If the power supply is interrupted during the programming phase, all the unsaved data
will be lost. It will therefore be necessary to repeat the operations from the beginning.
Likewise, if you realise that you have made an error, just switch the panel off and then on again and start from
the beginning.
60
CALIBRATION OF THE EXTENSOMETER FOR A PORELLO
BASKET CLASS 3
9 Set the machine as it should work with the basket, WITHOUT PUTTING ANY LOAD IN IT.

9 Open the top cover of the panel where the electric card is (the wires of the extensometer and of the
electricity supply are connected to this card).

YELLOW LED D21 (SWITCH SW1)

RED LED D20 (SWITCH SW2)

GREEN LED D19 (SWITCH SW3)

1. Switch on the machine, the SW1 yellow led will start flashing.

2. Push SW1, the SW2 red led will begin to flash, while the yellow one will be steady turned on.

3. Push SW2

4. Load the charge, which will have to be equal to the maximum load capacity of the the basket.

5. Push SW3 (green led), the yellow led will be steady on and the red one will keep on flashing.

6. Push SW1, all led will be switched off. Calibration successfully completed.
61
CONNECTING LOAD SENSORS WIRES

2nd SECURITY
1st LOADING
LOAD SENSOR SENSOR.
to be calibrated to be calibrated
(black covering) (grey covering)

1st SENSOR
CARD

R N B G

R N V B

WIRES

2nd SENSOR
CARD

X X B R N V

WIRES

If the basket shouldnt be in the condition of making any kind of movement, invert the wires in the 3rd
and 4th position, connected to the five-poled grey plug

BLAK 1 5 4 RED

GRAY RED 2 3 RED


62
Old Cab New Cab
1.3E.47814 87.00 1.3E.1606006V-A rear window 67.98
2. 3E.47815 223.70 2. 3E.1606002V-B open roof glass 50.99
3. 3E.47816 44.40 3. 3E.1606004V-B glass behind door 50.99
5. 3E.47818 88.78 5. 3E.1606001V-B windscreen 271.92
6. 3E.47819 227.24 6. 3E.1606003V-C front right side 115.19
7. BSC0199 7.01 p.m. 6. 3E.1606005V-C rear right side 47.59
8. BSC0199 9. 3E.1606004V-B rear left side 50.99
10. BSC0199 3E.1606008V-A fixed door glass 61.19
12. BSC0199 3E.1606007V-C openable door glass 88.58
15. BSC0157 3.75
16. BAE1252 1.20

Rear window Wiper old cab Windscreen Wiper Old Cab


3E.51056 Wiper motor 129.28 3E.51060 motor 113..05
3E.51057 wiper arm 22.51 3E.51061 arm 47.95
BEQ0111 wiper blade 9.08 BEQ0112 blade 15.24
Roof wiper old and New Cab Windscreen wiper New Cab
3E.51052 motor 113.05
3E.31393 motor 169.25
3E.51053 arm 22.51
3E.31394 arm 84.98
BEQ0111 blade 9.08
3E.31395 blade 17.00

Old Cab New Cab


3. 3E.61033 1295.94 3. 3E.31420 complete door 1607.75
34. 3E.61012 71.02 34. 3E.61012 window clasp 71.02
44. 3E.61037 50.29 51. 3E.1606019C hinge 33.99
51. 3E.61038 19.25 52. 3E.91019 handle 31.27
52. 3E.62019 31.27 55. BSC0070 check strap 9.79
55. BSC0070 9.79 56. 3E.1606019C hinge 33.99
56. 3E.61039 19.55 58. BSH9109 stop 7.58
58. BSH9109 7.58 Door catch on cab post BSC0159 12.36
door glass 3e.61036 142.03 Door Lock
Door lock 49. 3E.31408 inner door handle 30.60
49. 3E31230 21.49 50. BWC1104 cable 2.95
50. BWC1104 2.95 51. 3E.31336 outer handle 88.38
51. 3E.61008 82.87 52. BAE1250 screw 0.06
52. BAE1250 0.06 53. 3E31407 inner door lock 67.98
53. 3E.61007 62.74 54. BAE3511 screw 0.10
54. BAE3511 0.10 55. 3E.31409 door lock key 5.10
55. BSC0048 2.95 4C.114014 Ignition key 6.80
Fuel Key BHG3031 6.22 BHG3031 Fuel key 6.27
Door ram BSC0169 43.22 3E.31225 door ram strut 40.79
Dedalus Door old Cab
Dedalus Door
3E.61062 Upper door glass 91.85
3E.1603011V main door glass 491.54
3E.61061 Main door glass+frame 683.48
3E.61060 Complete door glass 1099.48
4. 3E.61012 window clasp 71.02
27. 3E.61038 upper door hinge 19.55
30. 3E.61063 main door hinge 19.61
42. 3E.61039 upper door hinge 19.55
44. 3E.61063 main door hinge 19.61
45. 3E.62019 upper door handle 31.27 Apollo cab Glass
47. BSC0070 door strap 9.79 3e.1614001V windsacreen
BSC0169 Door strut ram 43.22 264.00
3e.1614002v lge door glass
New Cab Machine Parts 46.20
Yellow fender BSH0015 93.96 3e.1614008v sm door glass
Forward reverse lever 4C.116107 288.92 38.30
Light switch lever 4C.116088 247.20 3e.1614009v reare glass 145.20
RPM dash Clock 4C.00015138 305.91 3e.1614010v left rear glass
Ignition switch 4C.109058 84.98 46.20
Over load sensor 4C.137031 339.90 3e.1614011v rt side glass
L H tail light 4C.110705 26.27 165.00
R H tail light 4C.110704 26.27 3e.1614012v opening door
L H tail light lens 4C.127082 19.78 81.00
R H tail light lens 4C.127081 19.78
Hand brake cable BWC1672 66.53
63
P.D.I. Check List
Company name Serial No
Owners Name Model.

Tick all Boxes Checked

Differential oil and reducer oil level Steering control system three way
Battery Level Brakes
Engine water level Foot throttle
Engine oil level Hand throttle
Brake fluid level Side shift lever
Hydraulic oil level Stabilisers
Axle and hub oil level Self levelling device
Engine belt adjustment Boom control levers
Check tightness of boom sliding shoes Direction Indicators
Air filter clogged indicator Parking brake
Wheel nuts tight Horn
Tyre condition Lights
Tyre inflation pressure Wiper front
Amount of fuel in tank Wiper rear
Grease drive shaft Wiper roof
Grease extending boom sections Windscreen washers
Grease all pins Screen washers rear and roof
Grease side shift Cab door adjustment
Check tightness of boom sliding shoes Test drive
Check tightness of rotation motor Pegasus Overload indicator tested
Diesel in tank Check q attach ram in h/stock
Tool kit and Handbooks Beacon

Grease Points Shown

Additional Extras Pick up hitch Window guards


Basket Shear grab
2 working lights front 3.8 ton winch Block grab
2 working lights rear 4.5 metre jib Auto Greaser
Radio 1.2 metre jib Stickers
Bucket Remote control Basket control
Forks Agri check valve Weld on Brackets
Quick attach forks bracket Spare wheel
Any Comments.

Mechanics SignatureDate..

Checked by Date .
64
Fuse panel New Cab Lay out
65
Fuses and relays in New cab Fuse Panel
66
Fuse and relay circuits New Cab Dieci

Fuses
F 27 -- fuse for engine stop solenoid, seat micro switch,
(some times if you slide the seat forward it is possible to pull the wires going to seat micro switch causing the
switch to come out of its base allowing it to touch the seat frame and blow this F27 fuse)
67

CEMENT MIXER TRUCKS SERIES 2005

HYDRAULIC COMPONENTS [PRESSURE N 2400 L 3500 L 4700 F 7000


ADJUSTMENTS]
MIN [bar] MAX [bar] MIN [bar] MAX [bar] MIN [bar] MAX [bar] MIN [bar] MAX [bar]
Loading tank and utilities control valve 170 180 170 180 170 180 170 180
Calibration pressure of the anti-collision valve on tank
80 80 80 80
control valve unit [DOWN]
Calibration pressure of the anti-collision valve on tank
170 170 170 170
control valve unit [UP]
Drum rotation circuit pressure 170 190 170 190 250 250

Hydrostatic pump high pressure circuit 420 430 420 430 420 430 420 430

Hydrostatic pump/engine displacement gear 220 ~ 220 ~ 220 ~ 220 ~

Hydrostatic pump boost pressure 24 27 24 27 24 27 24 27

Inching circuit pressure 5 24 5 24 5 24 5 24

Power steering circuit pressure 165 170 165 170 165 170 165 170

Supply pressure of gear change solenoid valve 24 27 24 27 24 27 24 27

Supply pressure of negative brake solenoid valve 24 27 24 27 24 27 24 27

Supply pressure of servo brake circuit 24 27

Water cleaner pump pressure (*) 110 120 (*) 110 120 (*) 110 120 (*) 110 120
68 To Change the pipes in a 4 part boom with chains
69
70
71
72
73
74
75
76
Icarus 38-14m internal Pipes

Part number BKX0998 x 4 pipes inside the boom all these are the same. 2 go to the tilt ram from the steel pipes on the under side of
main boom. 2 go to auxiliary fittings on headstock from the steel pipes on the under side of main boom.

To remove these pipes:

1. Boom down horizontal and fully retracted.


2. Remove rear cover to expose inside of boom area
3. Loose of pipe or pipes to be replaced at under side of main boom attach a rope to each of these for drawing the new pipes back in.
4. Pull the pipe or pipes out the rear and un attach the rope leaving it in the boom
5. At the front remove the inspection plate from the headstock giving access to the top of the tilt ram.
6. Unscrew pipe or pipes to be replaced and attach a rope to each pipe as these need to be removed one at a time. These pipes are
held in the boom by a channel down each side of the boom 2 pipes in one side and 2 pipes and an electric cable in the other
7. Remove pipe via the rear, guiding the front end with rope into the channel at the front of the boom.
8. Replace the new pipes in reverse order.

The pipes them selves are of the following dimensions

Length 35 ft 6 inches, not counting end fittings.


90 degree BSP inch female fitting on one end
90 degree metric 24 female fitting on the other end
Both fittings facing the same direction.

Icarus 16m Boom Pipes, Part no. BKY1998

On the 16m there is a cage system in the boom to keep the pipes together. If you want to replace one pipe you have to remove all the
pipes and electric cable in one piece. The lower section of the pipe work from the steel pipes on the out side front section of main
boom can be replaced separately from the section inside the inner boom.

To remove pipes from lower part of boom

1. Lower the boom and retract the boom in fully


2. Remove cover of the rear end to expose the inside of boom.
3. Un screw pipes from steel pipes on the front under side of main boom section
4. Attach ropes to the pipes to be removed (on this section you can remove one pipe as needed)
5. Loose of the roller at the rear and remove out of way
6. Unscrew the pipes at the rear and pull out the rear feeding the rope though as you go
7. Replace new pipes in reverse order.

To replace pipes in the inner section

1. Lower the boom and retract the boom in fully


2. Remove cover of the rear end to expose the inside of boom.
3. Remove inspection plate from the front headstock.
4. Un screw the pipes from the auxiliary fitting and the tilt ram (it may be necessary to take the pin from the top of tilt ram to let
it drop down for ease of access).
5. Disconnect the electric wire from the front head stock
6. Attach ropes to the pipes and electric cable. (To be used for pulling in the new pipes and cable)
7. At the rear remove roller system and disconnect pipes
8. Remove four 6mm bolts from lower mounting bracket of cage
9. Remove side retaining brackets that hold pipes
10. Remove two 8mm studs and nuts that hold upper mounting bracket of cage
11. Remove the pipes and electric cable from the top first. (It will be necessary to push the lower part back in off the step it is
mounted on to get it out)
12. Pull the remaining part of pipes and cable out feeding rope through as you do so (to change the electric cable it will be
necessary to disconnect from control box)
13. Replace pipes in reverse order

The pipes them selves have the following dimensions

Length 33ft. 6inches, not counting the fitting ends


90 degree BSP inch female fitting on one end
Straight metric 24 female fitting on other end

Dieci Hyd Hose details


77

BKX0998 14m internal boom hose


Length 35 ft 6 inches, not counting end fittings. (2LW hose 21mm dia.)
90 degree BSP inch female fitting on one end
90 degree metric 24 female fitting on the other end
Both fittings facing the same direction.

BKY1998 16m internal boom hose


Length 33ft. 6inches, not counting the fitting ends (2LW hose 21mm dia.)
90 degree BSP inch female fitting on one end
Straight metric 24 female fitting on other end

BKX0987 8m internal boom hose


Length 8700mm not counting fitting ends (2LW hose 21mm dia.)
90 degree BSP inch female fitting on one end
90 degree metric 24 female DLM fitting on the other end
Both fittings facing the same direction.

BKY1986 Zeus 35-10 internal boom hose


hose 1/2 2LW ext dia= 21mm L= 8700mm
inch female BSP 90 degree on one end
24 metric female straight on other end

BKY1992 17m Icarus 34 ft 10inches 24m st - bsp 90 degree

BKY1987 26ft 2 inches 24m st - bsp 90 degree

BKY1986 28ft 7 inches 24m st - bsp 90 degree

BKY1995 37 ft 0 inches 24m st - bsp 90 degree

BKY1994 40ft 6 inches 24m st - bsp 90 degree

Main Transmission hoses Dedalus 26-6


Long hose part number BLF6155/66
4 wire hose WP420 bar (hose length not counting ends) 150cm
Clamp type ends with 90 degree bends on both, facing the same direction
1st end 1 5/8 inches (41mm) across the diameter of fitting face, with o ring inserted
2nd end 1 7/8 inches (48mm) across the diameter of fitting face, with o ring inserted

Short hose part number BLF6085/54


4 wire hose WP420 bar (hose length not counting ends) 73cm
Clamp type ends with 90 degree bends on both, facing off set by 90 degrees one from the other
Ends the same as the above hose

1 7/8 1 5/8
78

Walvoil products training

WALVOIL PER DIECI s.r.l.

Data / Date: Inserire la data


Autore / Author: Inserire lautore

Walvoil products training


DIECI s.r.l.

Schema idraulico

Data / Date: Inserire la data 2 di / of ...


Autore / Author: Inserire lautore
79
Walvoil products training

From outside
MAXIMUM PRESSURE VALVE

ANTISHOCK VALVE

CONSENSE BUTTON VALVE

Data / Date: Inserire la data 3 di / of ...


Autore / Author: Inserire lautore

Walvoil products training

to inside
EXTENSION SPOOL
SERVICE SPOOL

LIFTING SPOOL
TILTING SPOOL

Data / Date: Inserire la data 4 di / of ...


Autore / Author: Inserire lautore
80
Walvoil products training

Cloche L.C.B.

Data / Date: Inserire la data 5 di / of ...


Autore / Author: Inserire lautore

Walvoil products training

Consense button valve

Data / Date: Inserire la data 6 di / of ...


Autore / Author: Inserire lautore
81
Walvoil products training

Maximum pressure valve

Data / Date: Inserire la data 7 di / of ...


Autore / Author: Inserire lautore

Walvoil products training

Antishock valve

Data / Date: Inserire la data 8 di / of ...


Autore / Author: Inserire lautore
82

Dieci Weld on Bracket

Radius 60 mm 390 mm centre to centre Icarus


350 mm centre to centre Dedalus
Radius 42 mm

250 mm centre to centre

Tongue for locking on implement

125 mm

200 mm

40 mm

50 mm
83

JCB Type Head stock

4
5
1
6
7
3
14 ram
8
2
11 9
12
13 10

6. JCB ram BHM0105 single rod 6. JCB ram BHM0035 with double rod
JCB Weld on bracket

57mm dia

Box section
62mm 10mm 100 x 100mm

650mm

10mm
40mm dia

32mm dia

25mm
Box section
100 x 100mm
46mm
84
Dieci Ltd
245 ARMAGH RD, NEWRY, CO. DOWN, NORTHERN IRELAND, BT35 6NL TEL 02830 821230 FAX 02830 821583
MOBILE: 07860 617616 E-MAIL: alan@dieci.org UK OFFICE NICK SHEARD: TEL 01262 420261
MOBILE: 077939 224092 E-MAIL: nick@dieci.org

16-03-04

Service Bulletin No 001


Ref: - Service schedules

We would like to stress the importance of regular servicing. In particular oil changes. It has come to our
attention that some machines are not getting oil changes in accordance to service schedules.

We would ask that you rigorously follow the service schedule, which recommends hydraulic oil changes every
1000 hours. We would ask you to inform the relevant departments in your business of this matter.

Though the problem of lack of oil changes has not arisen within the warranty period it will shorten the expected
life of transmission pumps, hydraulic pumps, motors etc. considerably, thus occurring cost to the owners that
could be avoided.

High Temperatures and high pressures (230 bar for hydraulics and 450 bar in the transmission) lead to the oil
having to work at a premium even with 130 litres in the smaller machines to 280 litres in the larger machines.
As Dieci use a mineral based oil we would also like to stress the importance of using Mineral based oil. Under
no circumstances use a synthetic oil as this will do damage. Oil working under these conditions will loose its
viscosity and additives over a period of time and though oil is there is quantity if it is not there in quality it
cannot do the many tasks asked of it in to-days machine.

A copy of the service schedule is enclosed.

If we can be of any further assistants please do not hesitate to call

Best Regards

Houston Milne
Service Manager
Dieci Ltd.
85
dDIECI Ltd
SERVICE DEPARTMENT 245 ARMAGH RD, NEWRY, CO DOWN, NOTHERN IRELAND, BT35 6NL
TEL: 02830 821230 FAX: 02830 821583 MOBILE : 07860 617616 E-MAIL: alan@dieci.org

17-03-04

Service Bulletin No 002


Ref: - Pegasus turret rotation motor.

In the service schedule for the Pegasus model we recommend that you include in the various checks section.
Check turret rotation motor bolts as there has been an incident of these bolts either been loose from the
factory or have come loose during operating.
It would also be good practice to incorporate this check in P.D.I. procedure.

Best Regards

Houston Milne
Service Manager
Dieci Ltd.

dDIECI Ltd
SERVICE DEPARTMENT 245 ARMAGH RD, NEWRY, CO DOWN, NOTHERN IRELAND, BT35 6NL
TEL: 02830 821230 FAX: 02830 821583 MOBILE : 07860 617616 E-MAIL: alan@dieci.org

17-05-05

Service Bulletin No 003


Dedalus Teleporters (serial numbers starting with 131.)
The hydraulic pressure on these machines should be checked to make sure they are not exceeding the
prescribed setting of 180 bar.
A higher setting could lead to excessive engine wear shortening the life of the engine.
This bulletin covers all the old cab Dedaluss no other model is affected.
Please make arrangements to check the maximum hydraulic pressure on all old cab Dedalus teleporters.
The correct pressure can be checked by taking a reading with the appropriate test clock plugged into the
auxiliary fitting on the front of the boom.

Best Regards

Houston Milne
Service Manager
Dieci Ltd.
86
dDIECI Ltd
SERVICE DEPARTMENT 245 ARMAGH RD, NEWRY, CO DOWN, NOTHERN IRELAND, BT35 6NL
TEL: 02830 821230 FAX: 02830 821583 MOBILE : 07860 617616 E-MAIL: alan@dieci.org

8/1/07

Service Bulletin No 004


Pegasus (all models)

Up grade of service schedule

On regular service schedule, add to each visit the following.

Check and replace, as necessary, the crystals bag in the electrical section of the rotation turret.

This bag can be found by lifting up boom and removing plate in the centre directly over the rotating axis.
Remove the doom shaped cover to reveal the electric contacts. The crystals bag can be found in the bottom of
this section.
Check if bag is dry and pliable, in this case all is well.
If the bag is hard, discoloured or damp it needs replacing
Also check for any corrosion on the contacts, clean as needed.

Best Regards

Houston Milne
Service Manager
Dieci Ltd.
87
dDIECI Ltd
SERVICE DEPARTMENT 245 ARMAGH RD, NEWRY, CO DOWN, NOTHERN IRELAND, BT35 6NL
TEL: 02830 821230 FAX: 02830 821583 MOBILE : 07860 617616 E-MAIL: alan@dieci.org

2/4/07

Service Bulletin No 005


40 km rd speed Machines all models.

Caution on Road Travel

All customers should be notified immediately, of the following information.fully

Machines with 40km ability


It has come our attention that some operators are allowing their machines to over speed beyond the 40km limit
& maximum 2500 RPM .
We would like to reiterate the importance of keeping the machine within the legal & safe travelling speed.
There is a danger that the machine may suffer severe mechanical damage & or personal injury to driver or
others, by driving and exceeding the machines maximum road speed of 40km or maximum engine revs of
2500rpm. This can only happen by operating the machine incorrectly, allowing the machine speed to go above
the max rpm engine speed as indicated by rev indicator on dash.
Special precautions must be taken when driving down hill, where the machine can gain more speed or more
rpms on the engine . Drivers must be aware that precautions are to be be taken / example ,Pegasus 21m
weight unladen is 17,000Kg,s ,Which will propel & excelerate the vehicle when driving down hills ,The same
applys to towing ladin trailors allowing for the extra weight when travelling down hills In these case,s
It is necessary to limit the engine rpm to 2000 rpm while travelling down hill.
If the driver is in any doubt of this, and to prevent over speed going down a steep hill or long slope he must use
a lower gear.
It is the responsibility of the owner to insure that only licensed & fully qualified drivers may operate this
equipment

Best Regards

Houston Milne
Service Manager
Dieci Ltd.
88

dDIECI Ltd
SERVICE DEPARTMENT 245 ARMAGH RD, NEWRY, CO DOWN, NOTHERN IRELAND, BT35 6NL
TEL: 02830 821230 FAX: 02830 821583 MOBILE : 07860 617616 E-MAIL: alan@dieci.org

2/4/07

Service Bulletin No 006


To the Dieci service and warranty department of all depots

All warranty issues relating to tyres fitted to Dieci machines are handled directly by the Tyre manufacturer.
Mitas are the preferred supplier to Dieci. Should you wish to discuss any tyre issues the manufacturer can be
contacted directly on Tel no 01553817740

.
The tyre manufacturers or Dieci will not be responsible for damage due to tyres being used
1. under inflated
2. over inflated
3. wheels out of line.
4. cuts or tares
5.

Please be aware that machines will come from the factory with tyres at an over inflated pressure, for transport
reasons only.

During the initial PDI and subsequent servicing all tyres should be inspected for correct pressure for working
conditions and wheel alignment checked.

To check the correct alignment of the wheels and tyres the following measurement must be obtained.
inside front rim to rim and inside rear rim to rim are equal.

Houston Milne
Service Manager
Dieci Ltd